Quality Assurance & Control Plan

Contents

1 Plan of Quality Assurance........................................................................................................2

1.1 Objective...........................................................................................................................2
1.2 Scope.................................................................................................................................2
1.3 References.........................................................................................................................2
1.4 Resource management......................................................................................................4
1.4.1 Organization Chart.....................................................................................................4
1.4.2 ROLES & RESPONSIBILITIES..............................................................................6
1.4.3 Resources...................................................................................................................9
1.4.4 Professional Competence...........................................................................................9
1.4.5 Quality Organization..................................................................................................9
1.5 Materials Management....................................................................................................10
1.5.1 RECEPTION OF MATERIALS.............................................................................10
1.6 Control of Processes........................................................................................................17
1.7 Distribution & Control of documents.............................................................................23
1.8 Equipment Calibration control........................................................................................23
1.9 Treatment of Non conformity Corrective & Preventive actions.....................................24
1.10 Training...........................................................................................................................24

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1 Plan of Quality Assurance

1.1 Objective

This Quality Plan is to define and develop the policy framework of the
System of Quality Assurance, for the performance of Installation,
commissioning and Testing.

1.2 Scope
The scope of works for this Civil, Architectural, Landscape, Structural, Mechanical and
Electrical works for KKIA brief; shall include planning & design, implementation, Cabinet
installation, commissioning, Testing , acceptance, equipment warranty, maintenance, and other
item of works necessary for the successful completion of works.

This Plan covers the following activities:

 Distribution and control of documents
 Purchasing, supply, reception, storage, and control of materials
 Carrying out Inspection Point Programs
 Treatment of the Non-Conformities identified
 Corrective and Preventive Actions
 Treatment of Claims and Customer Complaints
 Control of Measurement Equipment

1.3 References

This Quality Plan is a result of implementing the System of Quality Assurance of I-Man Co,
inspired by the ISO- 9001 certificate as below, as part of the basic documentation:
 I-Man Co. Quality Manual
 Instructions from the I-Man Co. Quality Management in force.
 Customer Technical Specifications
 Customer Technical Specifications indicated in the service contract

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Certificate need to Attach 👇

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 1.4 Resource management

1.4.1 Organization Chart

Below is the Organization chart for the project Implementation of infrastructure Upgrade project
in KKIA.

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1.4.2 ROLES & RESPONSIBILITIES

The roles and responsibilities described below relate to personnel performance in terms of quality
during the execution of the works, without excluding any other job assigned to them.

PROJECT MANAGER
 Will perform the coordination tasks between the personnel comprising the different areas
of the project, monitoring the technical requirements required by the client as well as the
detailed schedule of project activities. In this regard, leading the work team and analyzing
the elements subsystems necessary for the proper functioning of the installation.
 Dialogue with the Proceedings Management on any issue related with the system and to
all matters related to the System Design, and all matters related to the technical quality of
the work and the personnel carrying it out.
 Responsibility for all activities performed on the project.
 Assume responsibility for compliance with the Quality Plan
 Promote and disseminate the Quality System among the personnel in their charge
 Planning and programming with the Site Manager, the human and material resources
necessary for the execution of the Works
 Promote, drive, and participate in the training tasks for Personnel and Collaborating Companies
 Keep up to date and properly filed and controlled the technical information,
specifications, plans, procedures, and technical instructions from the Customer applicable
to the work contracted.

SAFETY MANAGER

 Provides appropriate safety and health, accident prevention, and investigation training for
managers and supervisors.
 Assists management in the annual inspection of workplaces to assure safe and healthful
conditions for workers. Prepares appropriate notices for management to issue for
abatement of any identified hazards.
 Provides promotional materials and develops and administers recognition systems to
promote safe and healthful work performance.

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  Assists management and supervisors in investigating accidents and developing
measures to prevent recurrences.
 Supports by recording all accident reports in a timely, complete, and accurate manner.
 Assures that claims for injuries are recorded in the Occupational Safety and Health
Administration log.

Procurement Manager

 Devise and use fruitful sourcing strategies

 Discover profitable suppliers and initiate business and organization partnerships
 Negotiate with external vendors to secure advantageous terms
 Approve the ordering of necessary goods and services
 Finalize purchase details of orders and deliveries
 Examine and test existing contracts
 Track and report key functional metrics to reduce expenses and improve effectiveness
 Collaborate with key persons to ensure clarity of the specifications and expectations
of the company
 Foresee alterations in the comparative negotiating ability of suppliers and clients
 Expect unfavorable events through analysis of data and prepare control strategies
 Perform risk management for supply contracts and agreements
 Control spend and build a culture of long-term saving on procurement costs

QA/QC MANAGER

 Perform all daily inspection and test of the scope and character necessary to achieve the
quality of construction required in the drawings and specifications for all works under the
contract performed ON or OFF site.
 Cary out inspection and checking for all quality related procedures in the site and ensures
activity at the site are as per approved method statement and inspection test plan.
 Coordinate with the consultant’s representative and Site in charge for inspection and
meeting about quality problems including the closure of Non-Compliance Report.

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  Report to the QA/QC Manager, control, and monitor all activities related to Quality
Management System, QMS.
 Taking care of QA/QC documents of the entire project including certificates, calibration,
test results, inspection requests, non-compliance reports and site instruction/observations,
permanent materials delivered and other QA/QC documents.
 Responsible for the quality and workmanship of every activity, thorough knowledge of
all phases of engineering construction relating to Civil, Architectural and Structural
discipline interfacing the multidisciplinary operations.
 Develop method statement for the activity including risk assessment and job safety
environmental analysis and Inspection Test Plan and Checklist based on specifications of
the project.
 Carry out Internal Audit at the site as scheduled in the Project Quality Plan.

Implementation Manager

 Administer everyday workflow of all implementation processes and provide technical

support to all associates.
 Coordinate with team to resolve all issues within required timeframe and recommend
appropriate changes to all policies and procedures and evaluate all implementation for
team.
 Monitor all implementation requests and administer staff working and assist team and
senior implementation managers and provide required coaching for same.
 Evaluate all management information reports and ensure achievement of all team
objectives and provide support to senior implementation manager.
 Evaluate all processes and provide technical support to all senior implementation
managers and establish all client configuration requirements.
 Collaborate with system integration team and ensure compliance to all client
requirements and provide appropriate training to clients and ensure efficient
implementation of all systems.
 Develop all processes and tools for customer implementation lifecycle and identify all
defects and provide an efficient interface with all marketing and technical departments.
 Maintain all project plans and ensure compliance to timeframe and collaborate with
stakeholders for all implementation processes.
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1.4.3 Resources

All materials used when carrying out the service and whose contribution is by I-Man Co. will
comply with the conditions outlined in the Technical Specification Document, and should be
approved by the Person Responsible from the Customer.

To choose suppliers who provide services that meet the specifications set by the Customer,
potential suppliers will provide sufficient data to ensure compliance with both the technical and
quality requirements in providing services that they offer.

1.4.4 Professional Competence

Personnel assigned to carry the tasks must have the following characteristics:
 Image and presence
 Specific training for the services
 Qualified and authorized personnel. Authorized and Trained Workers Training Course.

1.4.5 Quality Organization

The original certificates of attendance on the course will be filed with the personal file of each
employee. During project implementation, the Quality Manager will have the material resources
necessary to carry out the checks and Inspection Points Program necessary (measuring and
testing equipment) and will also have an administrator to control documentation.

QUALITY
MANAGER

SITE RECEPTION,
MANUFACTURING INSTALLATION AND
PROCESS COMMISIONING
PROCESS

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1.5 Materials Management

All materials used in the work will comply with the conditions outlined in the Project and the
requirements of the Technical Specifications and should be approved by the Project Manager.

To choose suppliers who provide materials that meet the specifications set by the Customer,
potential suppliers will provide sufficient data to ensure compliance with both the technical and
quality requirements in providing the materials that they offer.

I-Man Co. will ensure that purchase orders contain all the quality requirements described in the
scope of the project.

Materials or equipment, being inspected or received, which do not meet specifications will be
rejected and returned to the Supplier, who shall return them within the shortest time possible.

Copies of all documents will remain stored in the purchasing department of the delegation, with
the necessary copies being sent to the Site Manager, which must also remain on file in the site
folder.

Both upon the receipt of materials to the stores and directly to the site, a delivery note of the
material provided will always be signed either by the store person or the person responsible for
the activity on site, who will have performed a visual inspection of the material received and will
sign the delivery order checking it against the related items and amounts.

The delivery note is delivered to purchasing so it can be checked with the order placed, and then
passed to the Site Manager to be signed.

1.5.1 RECEPTION OF MATERIALS

The materials to be installed, with significant impact on the quality and reliability of the
installation, will be inspected and tested with regard to the requirements specified in the project.
The same may be done at the supplier's facility or approved laboratories.

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These will be received with their respective Certificates of Quality and / or Testing protocols
carried out and verified in relation to the standards applied.

In general, and not restricted to, it is established what is hereafter indicated, having clarified
concerted options determined by the Works Manager.

In order to verify that the activity is in accordance with the requirements, four types of work unit
controls are applied:
 Visual reception on Site
o Checking physical match with those defined in the project
o Checking geometric dimension
o Finish check
 Geometric dimension check : intended to verify that the critical dimensions of the
elements are in line with plans or other project documents
 Technical Reception of Materials at Source and on Site: aimed at verifying that the
materials to be installed meet the requirements defined in the project or Technical
Specification document. The technical reception can be carried out at:
o The factory
o In the supplier's warehouse
o In an accredited laboratory
o On site
 Checks on the assembly phase: to check that the work units during assembly
meet that specified in the project, Implementation instructions and Inspection Points
Program.
 Final checks and tests: list of tests to be performed in the finished installation to
verify that it complies with the specifications in the project and the Technical
Specifications Document.

Factory Acceptance Test (FAT)

Note: Below are the sample tests performed for the previous projects. Below samples of
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tests are for indicative or reference purpose only. Exact tests required for this project will
be submitted after the award of contract.
The factory acceptance will be performed to determine that all Power system meets the
requirements and specifications of a contract before it is moved to its destination site. The FAT
will include performance, physical tests that are designed to verify that the equipment functions
properly before it's shipped out

 The following procedure will be included, but is not be limited to:

o Verify quality and quantity of all equipment specified in the documentation.
o Verify correct installation and powering-up of all hardware.
o Demonstrate all system functions.
o Conduct functional test.
o Fault management
o Network redundancy and management
o Support systems
o Interface requirements with Remote site capabilities

 Factory Acceptance test will include and demonstrate the following:

o Test equipment for all environmental, control and functions
o Test of Management System.
o Tamper tests of devices.
o Proper function of the integration function.

The FAT will be divided into the following three types of tests:

a) Structured tests (I-Man Co)

b) Unstructured tests
c) Reliability test (continuous operation of the System over a period of 30 days, with no
failure allowed, to give an indication of the System’s ability to meet the availability
requirements).

Sample FAT as was done in other projects, however I-Man Co. will conduct FAT &
SAT as per RFP requirement”

Cabinet FAT
Date:
Customer:
Project
Name:
Equipment Model:
Equipment Serial
No.: Engine Model:

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Engine Serial
No.:
Voltage: Rating:
Frequency:
Phase:

Item No. Description / Features Remarks

A. General & Operator

Interface: Manual Start
& Stop
Auto / Remote Start Auto
LED Not in Auto LED
Manual LED Common
Shutdown LED Common
Warning LED
Emergency Stop
Remote start active LED
B.
Fault Reset
Measurement and

Instrumentati
on Oil
Pressure
Water
Temperature
Engine Speed
Hours Run
Number of start
Battery Voltage
Voltage – 3ph L-L &
L-N Frequency

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3 ph Current

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PROTECTION AND ALARM CHECK:

Message LED Status Remarks

Low Oil Pressure Warning
High Coolant Warning
Temperature
Low Coolant Temperature Warning
Low Battery Voltage Warning
High Battery Voltage Warning
Bat. Alternator Charge Warning
fault
Over Crank ( failure to Shutdown
start )
Over Speed Shutdown
High Coolant Shutdown
Temperature
Low Oil Pressure Shutdown

Sample FAT as was done in other projects, however ACES will conduct FAT & SAT
as per RFP requirement”

LOAD TEST:
Load test will be carried out 15 min 25% load, 15 min 50% load, 15 min 75% load and for 1 hour 100%
load and all parameters will be logged in the attached load test report.

GENERATOR SET LOAD TESTING (See attached Sheet)

AMPERES VOLTAGE
OIL WATER
DURATION LOA KW L1 L2 L3 L1 L2 L3 FREQ PRESS. TEMP.
D .
(%K
W)

REMARKS
TESTED BY : WITNESS BY : APPROVED BY:

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UPS FAT

Sample FAT as was done in other projects, however ACES will conduct FAT & SAT
as per RFP requirement”

UPS Number PRODUCTION ORDER

UPS - FACTORY ACCEPTANCE
TEST
TEST MODALITY CHECKS Remarks
STANDARD TEST (1)
Visual inspection
- Physical inspection of
UPS cabinet
- Layout configuration and

1 cabinet disposition
- Disposition of UPS
components (rectifier,
inverter,
transformer, coils, etc.)
- Accessibility to operating
switches
- Information available on
“Operating Manual”
UPS functionality and
available
measurement data on display
- Start-up and Shutdown
operation
- Bypass mains data
2 - Rectifier data
- Battery data
- Inverter data
- Load information
- Alarm indications
including Temperature
Alarms &
Shutdown
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 - Messages indications
- Customer interface
information
UPS setting data
3 - Rectifier technical data
- Inverter technical data

UPS efficiency By using a Wattmeter,

4
- 100% load output and input power
are measured.
Distortion factor of output By using a harmonics
5 voltage analyzer the UPS output
- 0% load
- 50% load voltage distortion is
- 100% load
measured at each
load level.

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6
Distortion factor of input
current and Power Factor
measurement
7 Dynamic variation of output
voltage due to load variation.
Commutation test
8 through static bypass
(inverter to mains)
Commutation by error
detect
9 Mains failure test
10 Control of phase symmetry
11 Frequency precision test
By using a harmonics
analyzer the UPS input
current distortion and PF
are measured.
The UPS output is
loaded by a load steps 0-
100% and vice-versa; the
inverter output voltage is
measured by the mean
on a cathode ray
oscillograph.
(1) Passed / Not-passed
The load is transferred
from inverter to bypass
and vice versa; the UPS
output voltage
is measured by a
cathode ray
oscillograph
that shows no
interruption on the load
power
supply
Input mains failure is
simulated by switching
of the input mains power
supply, the load is
supplied by the battery;
the UPS output
voltage is measured by a
cathode ray oscillograph
that shows no
interruption
on the load power supply.
The UPS is loaded by
symmetrical and
nonsymmetrical
load; the UPS
output voltage
symmetry is
measured.
Input mains (bypass) is
locked, the inverter is
working in free running
way without any
synchronization to input
mains; inverter output
frequency shifting is
measured
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 Short circuit at UPS
12 terminals is realized; the
Short circuit test UPS output current and
voltage are measured by
a cathode ray
oscillograph, showing
the UPS short circuit
capability
during fuse blowing.
13 The UPS is loaded at
Overload test at 150% 150%; the overload time
is measured.
Disconnection and
connection of a unit
14
Test on parallel from the parallel system.
units (if Failure simulation of one
applicable) unit in parallel system.
Load sharing
between/among the
paralleled
units.
(1) Passed / Not-passed
15 Additional tests
(1) Passed / Not-passed

Testing site Date Tested by Signature Client Client representative

signature
Company name

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1.6 Control of Processes

IMPLEMENTATION ON THE SITE

Drawings provided by the Customer for the execution of the work will be controlled and
distributed to staff responsible thereof.
A copy of the site drawings will be delivered to Collaborating Companies and they will sign,
acknowledging receipt.

Likewise, the Site Manager:

 Will verify the documentation received.
 Remove materials from storage.
 Will discuss with the personnel in the workplace the work to be done.
 Will have a copy of the Procedures to be applied.
 Will organize the Work Plan.
 Will discuss with the Project Manager Changes or modifications of the work.

Will inform the Customer in writing of the anomalies or deficiencies detected in equipment and
materials supplied by him for use and assembly in the work carried out by I-man Co.

SITE REFORMS AND EXTENTIONS

Where work arises on the site not covered by the scope of the contract, the client customer shall
be informed, to determine, primarily, the impact on the contractual terms (quality, delivery of the
work, materials affected or to be acquired again, etc.) carrying out the economic valuation of the
same, requesting the acceptance and approval of the customer.

Before that work, the Project Manager or person responsible for the activity or (failing that)
should ask for confirmation and approval from the Client or his Representative to initiate these
upgrades.

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Copies of the documentation generated as a result of the Reforms and extensions (orders,
invoices, certificates of materials, modified drawings, equipment operation manuals ) as well as
prices contracted and approved by the customer, must remain on file in the site folder.

TESTING AND COMMISSIONING

According to the type of work or project tests, which are specified in accordance with the
applicable procedures, will be carried out, and evidence of their execution shall be left in the site
folder.
Likewise, it will be checked that the measuring equipment used is calibrated and the reference of
the measuring equipment used to obtain the test results shall be recorded.

Note: Below are the sample tests performed for the other projects. Below samples of tests
are for indicative or reference purpose only. Exact tests required for this project will be
submitted after the award of contract.
Site Acceptance Test (SAT)

Sample SAT as was done in other projects, however I-Man Co. will conduct FAT &
SAT as per RFP requirement”

SAT
Date:
Customer:
Project
Name:
Equipment Model:
Equipment Serial
No.:
Engine Model:
Engine Serial
No.:
Voltage: Rating:
Frequency:
Phase:

Item No. Description / Features Remarks

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A. General & Operator
Interface: Manual Start
& Stop
Auto / Remote Start Auto LED

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 Not in Auto LED Manual
LED Common Shutdown
LED Common Warning
LED Emergency Stop
Remote start active LED
Fault Reset
Measurement and
B.

Instrumentati
on Oil
Pressure
Water
Temperature
Engine Speed
Hours Run
Number of start
Battery Voltage
Voltage – 3ph L-L &
L-N Frequency
3 ph Current

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PROTECTION AND ALARM CHECK:

Message LED Status Remarks

Low Oil Pressure Warning
High Coolant Warning
Temperature
Low Coolant Temperature Warning
Low Battery Voltage Warning
High Battery Voltage Warning
Bat. Alternator Charge Warning
fault
Over Crank ( failure to Shutdown
start )
Over Speed Shutdown
High Coolant Shutdown
Temperature
Low Oil Pressure Shutdown

LOAD TEST:
Load test will be carried out 15 min 25% load, 15 min 50% load, 15 min 75% load and for 1
hour 100% load and all parameters will be logged in the attached load test report.

Sample SAT as was done in other projects, however I-Man Co. will conduct FAT &
SAT as per RFP requirement”

GENERATOR SET LOAD TESTING (See attached Sheet)

AMPERES VOLTAGE
OIL WATER
DURATION LOA KW L1 L2 L3 L1 L2 L3 FREQ PRESS. TEMP.
D .
(%K
W)

REMARKS
TESTED BY : WITNESS BY : APPROVED BY:

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UPS SAT

Sample SAT as was done in other projects, however I-Man Co. will conduct FAT &
SAT as per RFP requirement”

UPS Number PRODUCTION ORDER

UPS - FACTORY ACCEPTANCE
TEST
STANDARD TEST TEST MODALITY CHECKS Remarks
(1)
Visual inspection
- Physical inspection of
UPS cabinet
- Layout configuration and

1 cabinet disposition
- Disposition of UPS
components (rectifier,
inverter,
transformer, coils, etc.)
- Accessibility to operating
switches
- Information available on
“Operating Manual”
UPS functionality and
available
measurement data on display
- Start-up and Shutdown
operation
- Bypass mains data
2 - Rectifier data
- Battery data
- Inverter data
- Load information
- Alarm indications
including Temperature
Alarms &
Shutdown
- Messages indications
- Customer interface
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 information
UPS setting data
3 - Rectifier technical data
- Inverter technical data

UPS efficiency By using a Wattmeter,

4
- 100% load output and input power
are measured.
Distortion factor of output By using a harmonics
5 voltage analyzer the UPS output
- 0% load
- 50% load voltage distortion is
- 100% load
measured at each
load level.
By using a harmonics
6
Distortion factor of input analyzer the UPS input
current and Power Factor current distortion and PF
measurement are measured.

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7 Dynamic variation of output
voltage due to load variation.
Commutation test
8 through static bypass
(inverter to mains)
Commutation by error
detect
9 Mains failure test
10 Control of phase symmetry
11 Frequency precision test
12
Short circuit test
The UPS output is
loaded by a load steps 0-
100% and vice-versa; the
inverter output voltage is
measured by the mean
on a cathode ray
oscillograph.
(1) Passed / Not-passed
The load is transferred
from inverter to bypass
and vice versa; the UPS
output voltage
is measured b y a
cathode r a y
oscillograph
that shows no
interruption on the load
power
supply
Input mains failure is
simulated by switching
of the input mains power
supply, the load is
supplied by the battery,
the UPS output
voltage is measured by a
cathode ray oscillograph
that shows no
interruption on the load
power supply.
The UPS is loaded by
symmetrical and
nonsymmetrical
load; the UPS
output voltage
symmetry is
measured.
Input mains (bypass) is
locked, the inverter is
working in free running
way without any
synchronization to input
mains; inverter output
frequency shifting is
measured
Short circuit at UPS
terminals is realized; the
UPS output current and
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 voltage are measured by
a cathode ray
oscillograph,
showing the UPS short
circuit capability during
fuse blowing.
13 The UPS is loaded at
Overload test at 150% 150%; the overload time
is measured.
Disconnection and
connection of a unit
14
Test on parallel from the parallel system.
units (if Failure simulation of one
applicable) unit in parallel system.
Load sharing
between/among the
paralleled
units.
(1) Passed / Not-passed
15 Additional tests
(1) Passed / Not-passed

Testing site Date Tested by Signature Client Client

Company name
representative signature

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SITE DOCUMENTATION
Copies of all documentation generated during the execution of the work shall remain on file in
the site folders, if it is necessary to give the client a final report, it shall be drawn according to
the above documentation, with the documents being extremely important:
 Reports of tests and trials
 Sketches and Drawings As-built
 Certificates of materials and equipment
 Equipment Operation and Maintenance Manuals
 Site Measurement and Certifications
 Reforms and Modifications
 Legalization and Licenses
 Site Management

1.7 Distribution & Control of documents

The Site Manager will be responsible for the distribution and control of documentation received
or generated in the Delegation, on the Management of Quality, including distribution of the
Quality Plan, work procedures or customer specifications.

1.8 Equipment Calibration control

The measurement equipment used during the execution of the Work shall be carefully controlled
and in optimum operating conditions, meeting the following requirements:
 Be calibrated for the date of use
 Have copies of calibration certificates
 Be taken in to account climatic conditions for use and storage.

The measurement report should include the serial number of the measuring equipment used and
the person who made the measurements.

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Measurement Equipment needing to be calibrated, will be sent to an official or recognized
laboratory prior to use, and which are used for isolation and grounding measurement equipment.

1.9 Treatment of Non conformity Corrective & Preventive actions

The Person in charge shall notify the Site Manager about any incident that represents an adverse
quality system, so it can be documented in the "Site Incident Book ", in order to analyze and
establish improvement actions to eliminate potential causes of such incidents or anomalies.

Periodically, the Site Manager with the Site Foreman will analyze the documented incidences
and set the corresponding Improvement Actions and the Non- conformities that arise. Copies of
this information will remain in the Quality System file.
If during the execution of the work materials or equipment are discovered with deficiencies that
could affect the final quality of work, such materials should be segregated and identified as
NON-COMPLIANT, and the Project Manager and Customer Service should be informed if
appropriate.

During internal audits the effectiveness of Actions taken and the resolution of the Non
Conformities and effectiveness of Corrective Actions implemented will be checked.
Similarly Preventive actions to be implemented must be documented, as well as their effectiveness.

1.10 Training
All people involved in the project, at the same time they receive the Quality Management
Training, will be informed about Quality Policy.

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